Suspension system with single moving element

Abstract

A suspension system for use with a vehicle comprising a control arm having an upper rear arm and a spring mounting plate integrally formed as a single member, a spindle extending outwardly from the upper rear arm, an air spring adapted to be mounted intermediate the spring plate and the vehicle, and a pivot assembly for pivotally mounting the control arm to the vehicle whereby the pivot assembly has a fist axis of rotation.

1. A suspension system for use with a vehicle comprising:
 a control arm having an upper rear arm and a spring mounting plate integrally formed as a single member; 
 a spindle extending outwardly from the upper rear arm; 
 an air spring adapted to be mounted intermediate the spring mounting plate and the vehicle; 
 an axle tube; 
 a pivot assembly which is secured to and extends away from the control arm and which is rotatably mounted within the axle tube for pivotally mounting the control arm to the vehicle whereby the control arm is rotatable relative to the axle tube; 
 a retainer which is within the axle tube and secured to the axle tube so that the pivot assembly is rotatable relative to the retainer; and 
 a stop of the pivot assembly which is within the axle tube and engages the retainer to retain the pivot assembly within the axle tube. 
 
     
     
       2. The suspension system of  claim 1  further comprising
 a weld window formed in the axle tube; and 
 a weld within the window which fixedly secures the retainer to the axle tube. 
 
     
     
       3. The suspension system of  claim 1  wherein the retainer is in the form of a retaining ring; and a portion of the pivot assembly is within the retaining ring. 
     
     
       4. The suspension system of  claim 3  wherein the pivot assembly comprises a cross tube having an end and an insert secured within the cross tube and extending outwardly beyond the end within the retaining ring. 
     
     
       5. The suspension system of  claim 4  wherein the stop is secured to the insert. 
     
     
       6. The suspension system of  claim 5  wherein the stop is in the form of a ring in which part of the insert is received. 
     
     
       7. The suspension system of  claim 4  further comprising a weld between the cross tube and insert which secures the insert to the cross tube; wherein the weld is adjacent the retainer. 
     
     
       8. The suspension system of  claim 4  wherein the insert is in the form of a sleeve. 
     
     
       9. The suspension system of  claim 8  wherein the stop is in the form of a ring which is secured to the sleeve. 
     
     
       10. The suspension system of  claim 1  wherein the stop is in the form of a ring. 
     
     
       11. The suspension system of  claim 1  wherein the pivot assembly comprises a cross tube having a first end within the axle tube and a second end outside the axle tube;
 the control arm is secured to the cross tube adjacent the second end; and 
 the retainer is between the stop and the first end of the cross tube. 
 
     
     
       12. The suspension system of  claim 11  further comprising an insert secured within the cross tube and extending outwardly beyond the first end of the cross tube; wherein the stop is secured to the insert. 
     
     
       13. The suspension system of  claim 11  wherein the retainer is in the form of a retaining ring. 
     
     
       14. The suspension system of  claim 1  wherein the pivot assembly has a first end within the axle tube and a second end outside the axle tube;
 the control arm is secured to the pivot assembly adjacent the second end; 
 the pivot assembly is rotatable about a first axis; 
 the pivot assembly comprises a first segment having a first outer diameter; and 
 the stop is secured to and extends radially outwardly from the first outer diameter of the first segment away from the first axis. 
 
     
     
       15. The suspension system of  claim 14  wherein the pivot assembly comprises a second segment having a second outer diameter greater than the first outer diameter; and
 the retainer is between the stop and second segment. 
 
     
     
       16. The suspension system of  claim 15  further comprising a first bushing or bearing which is mounted on the second segment within the axle tube adjacent the retainer and by which the pivot assembly is rotatably mounted within the axle tube. 
     
     
       17. The suspension system of  claim 16  wherein the pivot assembly comprises a third segment having a third outer diameter greater than the second outer diameter; and further comprising
 a second bushing or bearing which is mounted on the third segment within the axle tube by which the pivot assembly is rotatably mounted within the axle tube. 
 
     
     
       18. The suspension system of  claim 1  further comprising a first bushing or bearing within the axle tube by which the pivot assembly is rotatably mounted within the axle tube. 
     
     
       19. The suspension system of  claim 18  wherein the first bushing or bearing abuts the retainer. 
     
     
       20. The suspension system of  claim 18  further comprising
 a second bushing or bearing within the axle tube by which the pivot assembly is rotatably mounted within the axle tube; 
 wherein the first bushing or bearing has a first outer diameter; and 
 the second bushing or bearing has a second outer diameter which is larger than the first outer diameter. 
 
     
     
       21. The suspension system of  claim 20  wherein the axle tube has a first inside diameter and a bearing surface defining a second inside diameter larger than the first inside diameter;
 the first bushing or bearing is within the first inside diameter; and 
 the second bushing or bearing is seated within the bearing surface. 
 
     
     
       22. The suspension system of  claim 1  further comprising
 an end of the axle tube; and 
 a washer mounted on the pivot assembly between the control arm and the end of the axle tube. 
 
     
     
       23. The suspension system of  claim 1  wherein when the axle tube is mounted on the vehicle, the axle tube extends from a driver side of the vehicle to a passenger side of the vehicle. 
     
     
       24. The suspension system of  claim 23  wherein the axle tube has a first end adjacent the driver side and a second end adjacent the passenger side;
 the control arm is a first control arm; 
 the upper rear arm is a first upper rear arm; 
 the spring mounting plate is a first spring mounting plate; 
 the spindle is a first spindle; 
 the air spring is a first air spring; 
 the pivot assembly is a first pivot assembly which is rotatably mounted within the axle tube adjacent the first end of the axle tube; 
 the retainer is a first retainer; 
 the stop is a first stop; 
 
       and further comprising:
 a second control arm having a second upper rear arm and a second spring mounting plate integrally formed as a single member; 
 a second spindle extending outwardly from the second upper rear arm; 
 a second air spring adapted to be mounted intermediate the second spring mounting plate and the vehicle; 
 a second pivot assembly which is secured to and extends away from the second control arm and which is rotatably mounted within the axle tube adjacent the second end of the axle tube for pivotally mounting the second control arm to the vehicle whereby the second control arm is rotatable relative to the axle tube; 
 a second retainer which is within the axle tube and secured to the axle tube so that the second pivot assembly is rotatable relative to the second retainer; and 
 a second stop of the second pivot assembly which is within the axle tube and engages the second retainer to retain the second pivot assembly within the axle tube. 
 
     
     
       25. A suspension system for use with a vehicle comprising:
 a control arm having an upper rear arm and a spring mounting plate integrally formed as a single member; 
 a spindle extending outwardly from the upper rear arm; 
 an air spring adapted to be mounted intermediate the spring mounting plate and the vehicle; 
 an axle tube; 
 a cross tube rotatably mounted in the axle tube for pivotally mounting the control arm to the vehicle so that the control arm is rotatable relative to the axle tube; 
 a retaining ring for retaining the cross tube adjacent the vehicle; 
 in which the retaining ring includes an inner sleeve secured to the cross tube, and a stop block mounted to the inner sleeve, and a lock sleeve secured intermediate the stop block and the cross tube.